Pumps put coolant under pressure
A
Wanner Engineering product story
Edited by the Engineeringtalk editorial team
Sep 19, 2005
Continuing investment in high pressure coolant delivery systems for machining operations on hard metals is paying big dividends for specialist UK tube assembly manufacturer, B and D Patterns .
Continuing investment in high pressure coolant delivery systems for machining operations on hard metals is paying big dividends for specialist UK tube assembly manufacturer, B and D Patterns.
Faster machining, fewer rejects and a spectacular increase in tool life are all contributing to rapid returns on investment, with payback times as short as 3 months.
Joint Managing Director Mark Burton estimates that productivity improvements associated with faster machining are averaging 45%.
The new systems - incorporating Wanner Hydra-Cell seal-less pumps - are supplied by Pumps and Equipment (Warwick), either as retrofits at the Hinckley, Leicestershire, factory of B and D Patterns or as specified equipment in new machines purchased for the plant.
As a manufacturer of pipe assemblies and components for aircraft engines used in civil aviation, B and D Patterns works with metals such as stainless steel, Inconel and titanium that can wear out tools very quickly.
Longer tool life was one of several potential benefits of high pressure coolant that prompted the company to open discussions with Pumps and Equipment - a supplier well experienced in this field, whose systems are based on the seal-less pump technology developed by Wanner.
A double advantage of the Hydra-Cell design in handling recirculated coolants is that the pumps are able to work at high pressure (up to 70 or 170bar, depending on the model chosen) and also tolerate small particles.
Unlike other types of high pressure pump that rely on seals - for example, piston, gear or screw pumps - they do not need ultrafine filtration.
That is already a big cost saving at purchase stage.
The pumps are simply constructed, easy to maintain and, with efficiencies of 80% or higher, they reduce energy costs by achieving high performance levels with relatively low power motors.
B and D Patterns put a Pumps and Equipment system to the test for the first time on a vertical machining centre, previously equipped with a 7-10bar coolant system for its drilling and milling operations.
At these low pressures, inefficient swarf removal was only one of its limitations.
"Within 3 months", says Mark Burton, "we recovered our investment".
"We cut cycle time by 35%, surface finish was improved, scrap rate was lower and tool life on some operations went up by 500%".
B and D Patterns, running more than 30 machine tools at Hinckley, has now retrofitted a number of them with 70bar systems using Hydra-Cell G10 pumps (one machine has a 140bar system, with the G04 model pump).
Three new machines also with Hydra-Cell based Pump and Equipment systems are in operation, with two more due for installation in the near future.
No reliability problems have been reported.
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